U.S. patent application number 12/650003 was filed with the patent office on 2010-07-15 for control circuit member and motor.
This patent application is currently assigned to ASMO CO., LTD.. Invention is credited to Nobuo MIZUTANI, Shingo OMORI, Mitsuhiro TAKADA, Hiroyuki TAKIKAWA.
Application Number | 20100176696 12/650003 |
Document ID | / |
Family ID | 42318549 |
Filed Date | 2010-07-15 |
United States Patent
Application |
20100176696 |
Kind Code |
A1 |
MIZUTANI; Nobuo ; et
al. |
July 15, 2010 |
CONTROL CIRCUIT MEMBER AND MOTOR
Abstract
A control circuit member provided in a motor is disclosed. The
motor includes a motor main body having a rotary shaft and a gear
housing integrated with the motor main body. The control circuit
member includes a circuit substrate on which a rotation detecting
element is mounted and a substrate support member. The circuit
substrate is accommodated in a circuit accommodating portion in the
gear housing. The substrate support member supports the circuit
substrate inside the circuit accommodating portion. The control
circuit member is configured to be insertable into the circuit
accommodating portion along the axial direction of the rotary
shaft. The circuit substrate is configured to be arrangeable inside
the circuit accommodating portion while being inclined with respect
to the axial direction of the rotary shaft, so as to cause the
rotation detecting element to approach the detector magnet.
Inventors: |
MIZUTANI; Nobuo;
(Toyohashi-shi, JP) ; OMORI; Shingo;
(Toyohashi-shi, JP) ; TAKADA; Mitsuhiro;
(Hamamatsu-shi, JP) ; TAKIKAWA; Hiroyuki;
(Kosai-shi, JP) |
Correspondence
Address: |
CAESAR, RIVISE, BERNSTEIN,;COHEN & POKOTILOW, LTD.
11TH FLOOR, SEVEN PENN CENTER, 1635 MARKET STREET
PHILADELPHIA
PA
19103-2212
US
|
Assignee: |
ASMO CO., LTD.
Shizuoka-ken
JP
|
Family ID: |
42318549 |
Appl. No.: |
12/650003 |
Filed: |
December 30, 2009 |
Current U.S.
Class: |
310/68B |
Current CPC
Class: |
H02K 2211/03 20130101;
H02K 7/1166 20130101; H02K 11/38 20160101; H02K 5/225 20130101;
H05K 1/18 20130101; H02K 11/215 20160101 |
Class at
Publication: |
310/68.B |
International
Class: |
H02K 11/00 20060101
H02K011/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 14, 2009 |
JP |
2009-006025 |
Jan 22, 2009 |
JP |
2009-011794 |
Claims
1. A control circuit member provided in a motor including a motor
main body having a rotary shaft and a gear housing, which is
integrated with the motor main body and accommodates a reduction
gear for reducing rotation speed of the rotary shaft, the control
circuit member comprising: a circuit substrate, which is
accommodated in a circuit accommodating portion provided in the
gear housing; a rotation detecting element mounted on the circuit
substrate, the rotation detecting element being arranged to face a
detector magnet that is provided on and rotate integrally with the
rotary shaft; and a substrate support member for supporting the
circuit substrate in the circuit accommodating portion; wherein the
control circuit member is configured to be insertable into the
circuit accommodating portion along the axial direction of the
rotary shaft, and wherein the circuit substrate is configured to be
arrangeable inside the circuit accommodating portion while being
inclined with respect to the axial direction of the rotary shaft,
so as to cause the rotation detecting element to approach the
detector magnet.
2. The control circuit member according to claim 1, wherein the
substrate support member includes: a base portion, which extends
parallel to the axial direction of the rotary shaft; and a
substrate attaching portion, which extends perpendicularly from the
base portion and includes a securing projection at the distal end,
wherein the circuit substrate includes a securing hole in which the
securing projection is inserted, and when the securing projection
is inserted in the securing hole, the circuit substrate is
assembled to the substrate support member with the circuit
substrate being inclined with respect to the substrate attaching
portion, and wherein the securing projection includes a first edge
close to the rotation detecting element and a second opposite to
the rotation detecting element as viewed from a widthwise direction
of the substrate support member, the first edge extending parallel
to the assembling direction of the circuit substrate, and the
second edge extending parallel to the extending direction of the
substrate attaching portion.
3. The control circuit substrate according to claim 1, wherein the
substrate support member includes an insertion portion in which an
electrical component mounted on the surface of the circuit
substrate facing the substrate support member is inserted.
4. The control circuit member according to claim 1, wherein the
substrate support member includes a terminal extending
perpendicular to the axial direction of the rotary shaft, and the
terminal is inserted in a terminal insertion hole formed through
the circuit substrate and is electrically connected to the circuit
substrate, and wherein the end of the terminal has an inclined
portion that allows the terminal to avoid contacting the part of
the circuit substrate where the terminal insertion hole is formed
when the terminal is inserted in the terminal insertion hole.
5. The control circuit member according to claim 4, wherein the
terminal includes a retained portion embedded in and retained by
the substrate support member, a joint connected to the circuit
substrate, and a bent portion formed between the retained portion
and the joint, and wherein the bent portion is not embedded in the
substrate support member and is exposed to the outside from the
substrate support member.
6. The control circuit substrate according to claim 5, wherein the
bent portion is a first bent portion and the terminal further
includes a second bent portion formed in the retained portion, and
the terminal is formed into a crank shape by the first and second
bent portion.
7. The control circuit member according to claim 6, wherein the
substrate support member includes a through hole, which extends
along the extending direction of the ends of the terminal, and the
first bent portion is exposed to the inside of the through
hole.
8. The control circuit member according to claim 1, wherein the
substrate support member includes an attaching portion engaged with
the inner wall of the circuit accommodating portion.
9. A motor comprising: a motor main body including a rotary shaft;
a gear housing integrated with the motor main body, the gear
housing accommodating a reduction gear for reducing rotation speed
of the rotary shaft; and a control circuit member accommodated in a
circuit accommodating portion provided in the gear housing, wherein
the control circuit member includes: a circuit substrate
accommodated in the circuit accommodating portion provided in the
gear housing, the circuit substrate being arranged to face a
detector magnet that is provided on and rotates integrally with the
rotary shaft; and a substrate support member for supporting the
circuit substrate in the circuit accommodating portion, wherein the
circuit accommodating portion is configured to receive the control
circuit member along the axial direction of the rotary shaft, and
wherein the circuit substrate is configured to be arrangeable
inside the circuit accommodating portion while being inclined with
respect to the axial direction of the rotary shaft, so as to cause
the rotation detecting element to approach the detector magnet.
Description
[0001] The present invention relates to a control circuit member
including a circuit substrate on which a rotation detecting element
is mounted, and to a motor provided with the control circuit
member.
BACKGROUND OF THE INVENTION
[0002] Conventional motors include a motor disclosed in, for
example, the specification of U.S. Pat. No. 5,245,258. The motor
includes a motor main body including a rotary shaft, a gear
housing, which accommodates a reduction gear for reducing the
rotation speed of the rotary shaft, and a control circuit member.
The gear housing is integrated with the motor main body. The
control circuit member is accommodated in a circuit accommodating
portion provided in the gear housing. The control circuit member
includes a circuit substrate, on which a rotation detecting element
(such as a Hall IC) for detecting rotation information of the
rotary shaft is mounted. The circuit substrate includes an element
mounting portion for mounting the rotation detecting element (such
as a Hall IC) on the circuit substrate. The rotation detecting
element needs to be arranged at a position near a detector magnet
that is provided on and rotates integrally with the rotary shaft,
and at a position facing the magnet. Thus, the element mounting
portion of the circuit substrate extends to the vicinity of the
detector magnet. The circuit substrate is assembled to the circuit
accommodating portion of the gear housing by inserting the circuit
substrate along the extending direction of the element mounting
portion (perpendicular to or inclined with respect to the axial
direction of the rotary shaft).
[0003] However, in the above-mentioned motor, the circuit substrate
is assembled to the circuit accommodating portion of the gear
housing along the direction perpendicular to or inclined with
respect to the axial direction of the rotary shaft, whereas the
motor main body and the gear housing are assembled along the axial
direction of the rotary shaft. Thus, the assembly of the circuit
substrate to the circuit accommodating portion is complicated.
SUMMARY OF THE INVENTION
[0004] Accordingly, it is an objective of the present invention to
provide a control circuit member in which a circuit substrate is
easily assembled to a circuit accommodating portion, and a
motor.
[0005] To achieve the above objective, a first aspect of the
present invention provides a control circuit member provided in a
motor. The motor includes a motor main body having a rotary shaft
and a gear housing, which is integrated with the motor main body.
The gear housing accommodates a reduction gear for reducing
rotation speed of the rotary shaft. The control circuit member
includes a circuit substrate, a rotation detecting element, and a
substrate support member. The circuit substrate is accommodated in
a circuit accommodating portion provided in the gear housing. The
rotation detecting element is mounted on the circuit substrate. The
rotation detecting element is arranged to face a detector magnet
that is provided on and rotates integrally with the rotary shaft.
The substrate support member supports the circuit substrate inside
the circuit accommodating portion. The control circuit member is
configured to be insertable into the circuit accommodating portion
along the axial direction of the rotary shaft. The circuit
substrate is configured to be arrangeable inside the circuit
accommodating portion while being inclined with respect to the
axial direction of the rotary shaft, so as to cause the rotation
detecting element to approach the detector magnet.
[0006] A second aspect of the present invention provides a motor
including a motor main body having a rotary shaft, a gear housing,
and a control circuit member. The gear housing is integrated with
the motor main body. The gear housing accommodates a reduction gear
for reducing rotation speed of the rotary shaft. The control
circuit member is accommodated in a circuit accommodating portion
provided in the gear housing. The control circuit member includes a
circuit substrate and a substrate support member. The circuit
substrate is accommodated in the circuit accommodating portion
provided in the gear housing. The circuit substrate is arranged to
face a detector magnet that is provided on and rotates integrally
with the rotary shaft. The substrate support member supports the
circuit substrate in the circuit accommodating portion. The circuit
accommodating portion is configured to receive the control circuit
member along the axial direction of the rotary shaft. The circuit
substrate is configured to be arrangeable inside the circuit
accommodating portion while being inclined with respect to the
axial direction of the rotary shaft, so as to cause the rotation
detecting element to approach the detector magnet.
[0007] Other aspects and advantages of the invention will become
apparent from the following description, taken in conjunction with
the accompanying drawings, illustrating by way of example the
principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention, together with objects and advantages thereof,
may best be understood by reference to the following description of
the presently preferred embodiments together with the accompanying
drawings in which:
[0009] FIG. 1 is a side view illustrating a motor according to a
first embodiment of the present invention;
[0010] FIG. 2 is a partial cross-sectional view illustrating the
motor of FIG. 1;
[0011] FIG. 3 is an exploded view illustrating the motor of FIG.
1;
[0012] FIG. 4A is a side view illustrating the control circuit
member provided on the motor of FIG. 1;
[0013] FIG. 4B is a partially enlarged view of FIG. 4A;
[0014] FIG. 4C is a partially enlarged view of FIG. 4A;
[0015] FIG. 4D is a front view illustrating the control circuit
member of FIG. 4A;
[0016] FIG. 5A is a side view illustrating a control circuit member
of a motor according to a second embodiment of the present
invention;
[0017] FIG. 5B is a front view illustrating the control circuit
member of FIG. 5A;
[0018] FIG. 5C is an enlarged view illustrating the connection
terminals of FIG. 5B and the vicinity thereof;
[0019] FIG. 5D is a cross-sectional view taken along line 5D-5D of
FIG. 5C; and
[0020] FIG. 6 is a partial cross-sectional view illustrating the
molding manner of the control circuit member of FIG. 5A.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] A first embodiment of the present invention will now be
described with reference to FIGS. 1 to 4D. A motor 1 shown in FIG.
1 is used in a power window apparatus for selectively opening and
closing the window glass of a vehicle. The motor 1 includes a motor
main body 2 and a reduction section 3, which reduces and outputs
rotation of the motor main body 2.
[0022] As shown in FIGS. 1 and 2, the motor main body 2 includes a
yoke housing (hereinafter, simply referred to as the yoke) 4, a
pair of magnets 5, an armature 6, a brush holder 7, and a pair of
power supply brushes 8. The yoke 4 is substantially flattened
cup-shaped, and the magnets 5 are secured to the inner surface of
the yoke 4. The armature 6 is rotatably supported by the yoke 4
inside the yoke 4.
[0023] The brush holder 7 is formed of resin material, and includes
a holder main body 7a, a flange portion 7b, an extended portion 7c,
a connector portion 7d, and a terminal support portion 7e. The
holder main body 7a, the flange portion 7b, the extended portion
7c, the connector portion 7d, and the terminal support portion 7e
are formed integrally. The holder main body 7a is arranged in the
yoke 4 in the vicinity of the opening of the yoke 4. The holder
main body 7a has a bearing 9, which rotatably supports the distal
end section of a rotary shaft 10 of the armature 6. The distal end
of the rotary shaft 10 projects to the outside of the yoke 4, and a
sensor magnet 10a (detector magnet) is secured to the projecting
portion via a metal plate 10b. The holder main body 7a also retains
the power supply brushes 8, which are arranged to slide along a
commutator 11 secured to the rotary shaft 10. The power supply
brushes 8 are arranged inside the yoke 4.
[0024] The flange portion 7b extends from the holder main body 7a
like a flange, that is, the flange portion 7b extends radially
outward about the rotary shaft 10. The extended portion 7c projects
radially outward from one end (rightward in FIGS. 1 and 2) of the
flange portion 7b along a flat surface 4a (see FIG. 1, a surface
parallel to the sheet of FIGS. 1 and 2) of the yoke 4, and the
connector portion 7d is formed on the distal end of the extended
portion 7c. A non-illustrated external connector can be fitted to
the connector portion 7d from the direction perpendicular to the
flat surface 4a (from the rear side of the sheet of FIGS. 1 and 2
in the direction perpendicular to the sheet). The terminal support
portion 7e extends from the extended portion 7c in the axial
direction of the rotary shaft 10.
[0025] Also, brush terminals 12 and connector terminals 13 are
embedded (insert molded) in the brush holder 7. The brush terminals
12 extend from the interior of the yoke 4 along the extended
portion 7c. The power supply brushes 8 are electrically connected
to the proximal ends of the brush terminals 12 via pigtails. The
connector terminals 13 extend from the connector portion 7d along
the extended portion 7c. The proximal ends of the connector
terminals 13 are exposed at the connector portion 7d, and form an
external connecting terminal 13a. When the external connector is
fitted to the connector portion 7d, the terminal of the external
connector is electrically connected to the connector terminals
13.
[0026] Also, the distal ends of the brush terminals 12 and the
connector terminals 13 extend from the terminal support portion 7e
along the axial direction of the motor main body 2 (downward in
FIG. 2), and are exposed to the outside. Parts of the terminals 12,
13 exposed to the outside form internal connecting terminals 14.
The internal connecting terminals 14 are arranged next to one
another along the direction perpendicular to the flat surface 4a
(perpendicular to the sheet of FIG. 2). Since the internal
connecting terminals 14 are arranged next to one another in the
direction perpendicular to the sheet of the drawing, only one is
shown in FIG. 2.
[0027] Also, the flange portion 7b, the extended portion 7c and the
connector portion 7d of the brush holder 7 are almost completely
covered by a waterproof member 15 formed of elastomer except the
part of the connector portion 7d corresponding to the external
connecting terminal 13a.
[0028] The reduction section 3 reduces the rotation speed of the
rotary shaft 10 of the motor main body 2. As shown in FIG. 1, the
reduction section 3 includes a gear housing 21, a worm shaft 22, a
worm wheel 23, a clutch 24 (see FIG. 2), a control circuit member
25, and a cover 26. The worm shaft 22 and the worm wheel 23 form a
reduction gear.
[0029] The gear housing 21 is formed of a resin material. The gear
housing 21 includes a securing portion 21a, a worm accommodating
portion 21b, a wheel accommodating portion 21c, and a circuit
accommodating portion 21d.
[0030] The securing portion 21a is formed into a shape that
corresponds to a flange portion 4b formed at the opening of the
yoke 4. The securing portion 21a is secured to the flange portion
4b with screws 27. The flange portion 7b of the brush holder 7 and
the waterproof member 15 are sandwiched by the securing portion 21a
and the flange portion 4b.
[0031] The worm accommodating portion 21b is cylindrical and
extends along the extension of the rotary shaft 10, and rotatably
supports the worm shaft 22 therein. Also, the clutch 24, which
drivingly connects the worm shaft 22 and the rotary shaft 10 to
each other, is provided inside the worm accommodating portion 21b
at a part close to the motor main body 2 as shown in FIG. 2. While
transmitting the drive power from the rotary shaft 10 to the worm
shaft 22, the clutch 24 locks rotation of the worm shaft 22 such
that drive power from the worm shaft 22 is not transmitted to the
rotary shaft 10. That is, the clutch 24 is provided to prevent the
motor 1 from being rotated by the force applied from the load.
[0032] The wheel accommodating portion 21c has a flat disk-like
shape, and the central axis of the wheel accommodating portion 21c
extends in a direction perpendicular to the longitudinal direction
of the worm accommodating portion 21b. The worm wheel 23 is
rotatably accommodated in the wheel accommodating portion 21c. The
worm accommodating portion 21b partially communicates with the
wheel accommodating portion 21c, and the worm shaft 22 meshes with
the worm wheel 23 at the communicating part. Also, the wheel
accommodating portion 21c is formed on the side of the worm
accommodating portion 21b opposite to the connector portion 7d,
that is, on the left side in FIG. 1. Also, a flat surface 21e of
the wheel accommodating portion 21c is formed to be parallel to the
flat surface 4a of the yoke 4. As the entire gear housing 21, the
surface viewed from the direction perpendicular to the flat surface
21e serves as a flat surface of the gear housing 21.
[0033] The circuit accommodating portion 21d is formed such that
the internal connecting terminals 14 are arranged inside the
circuit accommodating portion 21d. More specifically, the circuit
accommodating portion 21d is formed on the side of the worm
accommodating portion 21b opposite to the wheel accommodating
portion 21c, and between the worm accommodating portion 21b and the
connector portion 7d. That is, the circuit accommodating portion
21d is formed in a dead space of the motor 1 in the structure
without the control circuit member 25. The inside of the circuit
accommodating portion 21d communicates with the part of the worm
accommodating portion 21b close to the motor main body 2 (part
corresponding to the sensor magnet 10a). Also, an opening 21f is
formed in the circuit accommodating portion 21d such that the
control circuit member 25 is insertable into the circuit
accommodating portion 21d from the direction along the axial
direction of the rotary shaft 10. The opening direction of the
opening 21f is set such that the opening direction (the direction
perpendicular to the opening 21f) is inclined with respect to the
axial direction of the rotary shaft 10 and the direction
perpendicular to the axial direction of the rotary shaft 10. The
opening 21f of the present embodiment is formed on a straight line
that connects the connector portion 7d and the distal end of the
worm accommodating portion 21b, that is, part of the worm
accommodating portion 21b opposite to the motor main body 2 as
viewed from the direction perpendicular to the flat surface of the
gear housing 21. The internal connecting terminals 14 of the brush
terminals 12 and the connector terminals 13 are arranged at a
position exposed to the outside as viewed from the opening
direction of the opening 21f. The control circuit member 25 is
substantially accommodated in the circuit accommodating portion
21d.
[0034] The control circuit member 25 includes a substrate support
member 31, which is secured to the circuit accommodating portion
21d of the gear housing 21, and a circuit substrate 32, which is
supported by the substrate support member 31 as shown in FIG. 2 and
FIGS. 4A to 4D.
[0035] The substrate support member 31 is formed of a resin
material, and includes a base portion 41, which extends parallel to
the axial direction of the rotary shaft 10. The base portion 41 is
formed into a frame-like shape and includes insertion portions 42a,
42b, which extend in a direction perpendicular to the axial
direction of the rotary shaft 10 as shown in FIG. 4D. The insertion
portion 42a is rectangular and located at a longitudinally middle
portion of the base portion 41. The insertion portion 42b is
located below the insertion portion 42a, and is formed as a notch.
A pair of press-fitting portions 43 (assembling portions), which
are press-fitted into the circuit accommodating portion 21d, are
formed on both widthwise sides of the base portion 41. Also, an
abutment portion 41a is formed on a first end of the base portion
41 in the longitudinal direction, that is, on the end of the base
portion 41 close to the motor main body 2. The abutment portion 41a
abuts against the terminal support portion 7e of the brush holder 7
in the axial direction of the rotary shaft 10 and the direction
perpendicular to the axial direction of the rotary shaft 10 (see
FIG. 2).
[0036] As shown in FIG. 4A, a pair of substrate attaching legs 44
(substrate attaching portions), which project in the direction
perpendicular to the axial direction of the rotary shaft 10, are
formed on the first end of the base portion 41. The substrate
attaching legs 44 are formed on both widthwise ends of the base
portion 41 (direction perpendicular to the sheet of FIG. 4A). In
FIGS. 4A and 4B, since the pair of substrate attaching legs 44 are
arranged next to one another in the widthwise direction of the
substrate support member 31 (perpendicular to the sheet of the
drawing), only one is shown. A securing projection 45 for securing
the circuit substrate 32 is formed on a distal end surface 44a of
one of the pair of substrate attaching legs 44. Also, a support
projection 46, which supports the second end of the circuit
substrate 32 in the longitudinal direction, that is, the end
portion opposite to the motor main body 2, is formed on the second
end of the base portion 41 in the longitudinal direction.
[0037] The circuit substrate 32 is supported by the substrate
support member 31 while being inclined with respect to the axial
direction of the rotary shaft 10. More specifically, the circuit
substrate 32 is inclined so as to approach the axis of the rotary
shaft 10 toward the first end in the longitudinal direction, that
is, toward the motor main body 2. An extended portion 32a, which
extends from the widthwise center of the circuit substrate 32, is
formed on the first end of the circuit substrate 32 as shown in
FIG. 4D. A rotation detecting element, which is a Hall IC 33, is
mounted on the distal end of the extended portion 32a. That is, the
circuit substrate 32 is supported in a state where the Hall IC 33
is inclined with respect to the axial direction of the base portion
41 so as to approach the sensor magnet 10a. The extended portion
32a is configured not to contact the brush holder 7.
[0038] The Hall IC 33 faces the sensor magnet 10a in the radial
direction. The sensor magnet 10a and the Hall IC 33 form a rotation
sensor for detecting the rotation information (such as the rotation
direction and the number of rotations) of the rotary shaft 10. The
Hall IC 33 detects field changes associated with the rotation of
the sensor magnet 10a, and outputs a detection signal to a control
section 34 mounted on the circuit substrate 32.
[0039] The circuit substrate 32 is assembled to the substrate
support member 31 while being inclined with respect to the
substrate attaching legs 44 of the substrate support member 31. As
the assembling method, the securing projection 45 of the substrate
attaching leg 44 is first inserted in a securing hole 32b formed in
the circuit substrate 32 (see FIG. 4B), and the circuit substrate
32 is subsequently secured to the second end (the longitudinal end
of the circuit substrate 32, and then the end opposite to the motor
main body 2) of the substrate attaching leg 44 by thermally swaging
the securing projection 45. The securing hole 32b is formed to
extend in a direction perpendicular to the surface of the circuit
substrate 32. Also, FIGS. 4A and 4B show the state before the
securing projection 45 is thermally swaged.
[0040] Also, a pair of securing portions 47, which are connected to
the second end of the circuit substrate 32 by thermal swaging, are
formed at a position slightly closer to the first end than the
support projection 46 of the substrate support member 31. The
securing portions 47 are formed on the widthwise ends of the
circuit substrate 32. FIG. 4A shows only one of the securing
portions 47.
[0041] The distal end surfaces 44a of the substrate attaching legs
44 are inclined so as to be in surface contact with the surface of
the circuit substrate 32 in a state where the circuit substrate 32
is inclined with respect to the substrate support member 31. The
securing projection 45 is circular as viewed from the extending
direction of the associated substrate attaching leg 44. As viewed
from the widthwise direction of the substrate support member 31
(the direction perpendicular to the sheet of FIGS. 4A and 4B), an
upper edge 45a (first edge) of the securing projection 45, that is,
the edge facing the Hall IC 33 is formed along a straight line that
is parallel to the assembling direction of the circuit substrate
32, and a lower edge 45b (second edge) of the securing projection
45, that is, the edge opposite to the Hall IC is parallel to the
extending direction of the substrate attaching leg 44. Thus, during
molding of the substrate support member 31, the securing projection
45 does not get caught by the mold when removing the mold of the
substrate support member 31 from the substrate support member 31 in
the extending direction of the associated substrate attaching leg
44. That is, the securing projection 45 is configured so as not to
be undercut. Also, as described above, since the upper edge 45a of
the securing projection 45 is formed along a straight line that is
parallel to the assembling direction of the circuit substrate 32,
the shape is suitable for the securing hole 32b of the circuit
substrate 32.
[0042] A projection 48, which projects toward the circuit substrate
32, is formed at the longitudinally middle portion of the base
portion 41. The distal end surface of the projection 48 is inclined
so as to be in surface contact with the surface of the circuit
substrate 32 in a state where the circuit substrate 32 is inclined
with respect to the substrate support member 31.
[0043] Control terminals 51, 52 are provided on the base portion 41
between the substrate attaching legs 44 and the projection 48.
Parts of the control terminals 51, 52 are insert-molded in the base
portion 41. The control terminals 51, 52 are arranged next to one
another in the widthwise direction of the substrate support member
31 (only those that are in the front of the sheet of FIGS. 4A and
4C are shown). The control terminals 51, 52 include first end
portions 56, which project from the base portion 41 toward the
circuit substrate 32, and second end portions 53, which project on
the side of the base portion 41 opposite to the circuit substrate
32. The first end portions 56 are inserted in terminal insertion
holes 32c (see FIG. 4C) formed to extend through the circuit
substrate 32, and are electrically connected to the circuit
substrate 32 by, for example, solder jointing. The second end
portions 53 are joined to the internal connecting terminals 14 by,
for example, Tig welding. The second end portions 53 are thus
electrically connected to the internal connecting terminals 14.
[0044] As shown in FIG. 4C, the terminal insertion holes 32c of the
circuit substrate 32 extend in a direction perpendicular to the
surface of the circuit substrate 32. An inclined portion 51c is
formed at the first end portion 56 of each of the control terminals
51. The inclined portion 51c is formed on the upper surface of each
first end portion 56, that is, on the surface facing the Hall IC.
The inclination angle of the inclined portions 51c is set in
accordance with the inclination of the terminal insertion holes
32c, that is, the inclination of the circuit substrate 32. Thus,
when assembling the substrate support member 31 on the circuit
substrate 32, the first end portions 56 of the control terminals 51
do not contact parts of the circuit substrate 32 that form the
terminal insertion holes 32c.
[0045] Various electrical components are mounted on both surfaces
of the circuit substrate 32. Electrical components 35 (such as a
relay) are mounted on the surface of the circuit substrate 32
facing the substrate support member 31, and the electrical
components 35 are inserted in the insertion portions 42a, 42b of
the base portion 41. Thus, the substrate support member 31 and the
circuit substrate 32 can be placed near each other, thereby
reducing the size of the control circuit member 25. Also, while
placing the substrate support member 31 and the circuit substrate
32 near each other, the base portion 41 is extended to the second
end of the circuit substrate 32 (the end close to the cover 26).
Thus, the base portion 41 supports the second end of the circuit
substrate 32. As a result, the circuit substrate 32 is stably
supported.
[0046] As shown in FIG. 3, the control circuit member 25 is
inserted from the opening 21f into the gear housing 21 (the circuit
accommodating portion 21d) along the axial direction of the rotary
shaft 10 with the motor main body 2 and the reduction section 3
assembled to each other. At this time, the press-fitting portions
43 of the substrate support member 31 are press-fitted in the
circuit accommodating portion 21d with the left and right ends of
the substrate support member 31 in FIG. 4D being held with a
non-illustrated jig. Thus, the control circuit member 25 is secured
to the circuit accommodating portion 21d. The width of the
substrate support member 31, that is, the dimension of the
substrate support member 31 in the left and right direction in FIG.
4D is previously set to be greater than the width of the circuit
substrate 32. Thus, the non-illustrated jig and the circuit
substrate 32 do not directly contact each other when holding the
substrate support member 31 with the jig. When the control circuit
member 25 is secured to the circuit accommodating portion 21d, the
distal end of the control circuit member 25 projects from the
opening 21f to the outside of the circuit accommodating portion
21d. As described above, the control circuit member 25 is assembled
easily since the control circuit member 25 is assembled along the
axial direction of the rotary shaft 10, which is the assembling
direction of the motor main body 2 and the reduction section 3.
Also, costs are reduced since special assembling equipment for
assembling the control circuit member 25 from the direction other
than the axial direction of the rotary shaft 10 is unnecessary.
[0047] When the control circuit member 25 is secured to the circuit
accommodating portion 21d, the internal connecting terminals 14 of
the brush terminals 12 and the connector terminals 13 abut against
the second end portions 53 of the control terminals 51. The second
end portions 53 of the control terminals 51 contact the internal
connecting terminals 14 at right angle (substantially L-shaped).
The second end portions 53 of the control terminals 51 and the
internal connecting terminals 14 are joined by, for example, Tig
welding as described above, and are electrically connected to each
other.
[0048] After joining the second end portions 53 of the control
terminals 51 of the control circuit member 25 to the internal
connecting terminals 14, the metal cover 26 is swaged and secured
to the circumference of the opening 21f of the gear housing 21 (the
circuit accommodating portion 21d) to close the opening 21f. The
cover 26 bulges by an amount corresponding to the projecting part
of the control circuit member 25 to form a space that accommodates
the part of the control circuit member 25 that projects from the
opening 21f to the outside of the circuit accommodating portion
21d. The cover 26 not only closes the opening 21f, but also
functions to receive heat generated by the control circuit member
25 and release the heat to the outside.
[0049] The present embodiment has the following advantages.
[0050] (1) In the present embodiment, the control circuit member 25
is inserted in the circuit accommodating portion 21d of the gear
housing 21 along the axial direction of the rotary shaft 10. The
circuit substrate 32 of the control circuit member 25 is inclined
with respect to the axial direction of the rotary shaft 10 to bring
the Hall IC 33 close to the sensor magnet 10a. Thus, while
arranging the Hall IC 33 mounted on the circuit substrate 32 to
face the sensor magnet 10a at a position close to the sensor magnet
10a, the circuit substrate 32 is easily assembled to the circuit
accommodating portion 21d.
[0051] (2) In the present embodiment, the second edge 45b of the
securing projection 45, that is, the edge opposite to the Hall IC
is parallel to the extending direction of the substrate attaching
legs 44 as viewed from the widthwise direction of the substrate
support member 31. Thus, when pulling out the mold of the substrate
support member 31 from the substrate support member 31 in the
extending direction of the substrate attaching legs 44, the
securing projection 45 is not undercut. Also, since the upper edge
45a of the securing projection 45, that is, the edge facing the
Hall IC 33 is parallel to the assembling direction of the circuit
substrate 32, the securing projection 45 is formed into a shape
suitable for the securing hole 32b of the circuit substrate 32.
[0052] (3) In the present embodiment, the insertion portions 42a,
42b are formed in the substrate support member 31 such that the
electrical components 35 mounted on the surface of the circuit
substrate 32 facing the substrate support member 31 are inserted in
the substrate support member 31. Thus, the substrate support member
31 and the circuit substrate 32 are brought close to each other,
and as a result, the size of the control circuit member 25 is
reduced. This also prevents reduction in the flexibility of layout
of parts that support the circuit substrate 32 on the substrate
support member 31, that is, the substrate attaching legs 44, the
support projection 46, the securing portion 47, and the projection
48. As a result, the circuit substrate 32 is stably held.
[0053] (4) In the present embodiment, the inclined portions 51c are
formed on the first end portions 56 of the control terminals 51.
The inclined portions 51c allows the first end portions 56 to avoid
contacting the terminal insertion holes 32c when assembling the
substrate support member 31 to the circuit substrate 32. This
allows the control terminals 51 to be arranged perpendicular to the
axial direction of the rotary shaft 10, thus facilitating the
manufacture of the substrate support member 31.
[0054] A second embodiment of the present invention will now be
described with reference to FIGS. 5A to 6. Like or the same
reference numerals are given to those components that are like or
the same as the corresponding components of the first embodiment,
and drawings and all or part of explanations are omitted.
[0055] As shown in FIG. 5A, the base portion 41 of the present
embodiment includes a terminal retaining portion 49 for retaining
the control terminals 51, 52 between the substrate attaching legs
44 and the projection 48. In the present embodiment, the total of
nine control terminals 51, 52 are embedded in the terminal
retaining portion 49.
[0056] The second end portions 53 of the control terminals 51, 52
are arranged next to one another in the widthwise direction of the
substrate support member 31 (see FIG. 5B). Also, the second end
portions 53 of the control terminals 51, 52 are parallel to the
extending direction of the substrate attaching legs 44.
[0057] As shown in FIG. 5D, retained portions 54 of the control
terminals 51, 52 are embedded in and retained by the terminal
retaining portion 49. The retained portions 54 each include a
second bent portion 55, which is bent substantially at right angle
with respect to the extending direction of the second end portions
53 of the control terminals 51, 52. Among the control terminals 51,
52, ones that are bent toward the first end of the base portion 41
at the second bent portions 55 are referred to as first control
terminals 51, and ones that are bent toward the second end of the
base portion 41 at the second bent portions 55 are referred to as
second control terminals 52. The number of the first control
terminals 51 is five, and the number of the second control
terminals 52 is four.
[0058] A first bent portion 57 is formed between the retained
portion 54 and the first end portion 56 of each of the control
terminals 51, 52. The first bent portion 57 is bent at right angle
with respect to the extending direction of the second end portions
53 of the control terminals 51, 52. A middle portion 58, which is a
part between the first bent portion 57 and the second bent portion
55 of each of the control terminals 51, 52, is parallel to the
longitudinal direction of the base portion 41, that is, the
vertical direction in FIG. 5D. Also, parts of the control terminals
51, 52 from the second bent portions 55 to the second end portions
53, and parts of the control terminals 51, 52 from the first bent
portions 57 to the first end portions 56, are parallel to the front
and rear direction of the base portion 41, that is, to a direction
perpendicular to the longitudinal direction of the base portion 41.
In other words, the parts are parallel to the left and right
direction in FIG. 5D. That is, the control terminals 51, 52 are
formed into a crank shape by the first and second bent portions 57,
55. Also, the retained portions 54 of the control terminals 51, 52
are bent into a crank shape in the widthwise direction of the base
portion 41, that is, in the left and right direction in FIG. 5B.
Thus, the positions of the first end portions 56 and the second end
portions 53 of the control terminals 51, 52 are displaced in the
widthwise direction of the base portion 41.
[0059] Through holes 49a corresponding to the control terminals 51,
52 are formed in the terminal retaining portion 49. The through
holes 49a are formed to extend through the terminal retaining
portion 49 in the extending direction of the second end portions 53
and the first end portions 56 of the control terminals 51, 52, that
is, in the front and rear direction of the base portion 41. The
middle portions 58 of the control terminals 51, 52 project from the
terminal retaining portion 49 into the respective through holes
49a, and the first bent portions 57 are formed at the projecting
portions. That is, the first bent portions 57 are configured to be
arranged in the through holes 49a. The first bent portions 57 are
not embedded in the substrate support member 31 and are exposed to
the outside from the substrate support member 31. That is, the
through holes 49a are formed at positions corresponding to the
first bent portions 57 of the control terminals 51, 52. Five
through holes 49a are formed closer to the first end of the base
portion 41 than the second end portions 53 of the control terminals
51, 52. Four through holes 49a are formed closer to the second end
of the base portion 41 than the second end portions 53 of the
control terminals 51, 52. Since the first bent portions 57 of the
control terminals 51, 52 are exposed in the through holes 49a as
described above, the first bent portions 57 do not contact the base
portion 41. Thus, parts of the control terminals 51, 52 from the
retained portions 54 to the first end portions 56 are flexible.
[0060] Each of the first end portions 56 of the control terminals
51, 52 projects from the corresponding through hole 49a toward the
circuit substrate 32. The first end portions 56 are inserted in the
terminal insertion holes 32b formed in the circuit substrate 32,
and joined with the circuit substrate 32 by, for example, solder
joints 61. The solder joints 61 electrically connect the control
terminals 51, 52 to the circuit substrate 32. Thus, the circuit
substrate 32 and the internal connecting terminals 14 of the motor
1 are electrically connected via the control terminals 51, 52.
[0061] As shown in FIG. 6, two molds 71, 72 are prepared when
integrally molding (insert molding) the control terminals 51, 52 on
the substrate support member 31. The control terminals 51, 52 are
placed in the molds 71, 72 and a resin material is poured into the
cavity formed between the molds 71, 72. In the present embodiment,
a first mold 71 supports the first end portions 56 of the control
terminals 51, 52, and a second mold 72 supports the second end
portions 53 of the control terminals 51, 52. The second mold 72 has
extended portions 72a, which extend toward the first mold 71 and
support the first bent portions 57 of the control terminals 51, 52.
After the resin material forming the substrate support member 31
has hardened, the first and second molds 71, 72 are removed from
the control terminals 51, 52 along the extending direction of the
first end portions 56 and the second end portions 53 of the control
terminals 51, 52, that is, in the front and rear direction of the
substrate support member 31. The through holes 49a are formed by
the extended portions 72a of the second mold 72. In this manner,
since the control terminals 51, 52 are bent into the crank shape by
the first and second bent portions 57, 55 in the present
embodiment, the first and second molds 71, 72 that are removed
along the extending direction of the first end portions 56 and the
second end portions 53 of the control terminals 51, 52 can be used.
That is, an integrally molded product of the substrate support
member 31 and the control terminals 51, 52 is molded with only the
first and second molds 71, 72 (upper and lower molds).
[0062] In the above-mentioned control circuit member 25, the
substrate support member 31 and the circuit substrate 32 might
expand and deform due to the heat inside the circuit accommodating
portion 21d. This generates, for example, stress that causes
positional displacement between the joints 62 of the control
terminals 51, 52 and the corresponding retained portions 54 along
the longitudinal direction of the base portion 41. In this case,
since the first bent portions 57 are formed between the joints 62
of the control terminals 51, 52 and the retained portions 54, the
stress concentrates at the first bent portions 57. Thus, excessive
force is not applied to the joints 62 of the control terminals 51,
52, which improves the stability of the electrical connection
between the joints 62 and the electrical components 35. Also, since
excessive force is also not applied to the terminal retaining
portion 49, the control terminals 51, 52 are stably retained.
[0063] The present embodiment has the following advantages.
[0064] (5) In the present embodiment, parts of the control
terminals 51, 52 from the retained portions 54 embedded in and
retained by the substrate support member 31 to the joints 62
connected to the circuit substrate 32 project from the substrate
support member 31, and the first bent portions 57 are formed at the
projecting portions. Thus, even when positional displacement occurs
between the joints 62 of the control terminals 51, 52 and the
retained portions 54 by the thermal expansion (or heat contraction)
of the circuit substrate 32 and the substrate support member 31,
excessive force is not applied to the joints 62 of the control
terminals 51, 52 joined to the circuit substrate 32. As a result,
the stability of the electrical connection between the joints 62
and the electrical components 35 is improved.
[0065] (6) In the present embodiment, the control terminals 51, 52
include the second bent portions 55 formed in the retained portions
54, and are bent into the crank shape by the first and second bent
portions 57, 55. Thus, the first and second molds 71, 72 can be
removed along the extending direction of the terminals 51, 52 when
integrally molding (insert molding) the control terminals 51, 52 on
the substrate support member 31, and the molding is performed with
only the first and second molds 71, 72 (upper and lower molds).
[0066] (7) In the present embodiment, the through holes 49a, which
extend along the extending direction of the first end portions 56
and the second end portions 53 of the control terminals 51, 52, are
formed in the substrate support member 31 such that the middle
portions 58 project from the base portion 41 of the substrate
support member 31. The middle portions 58 are the projecting parts
of the control terminals 51, 52 including the first bent portions
57. Thus, arranging the projecting parts of the control terminals
51, 52 including the first bent portions 57 in the through holes
49a formed in the substrate support member 31 reduces the influence
on the outer shape of the substrate support member 31. This
increases the flexibility of design of the outer shape of the
substrate support member 31.
[0067] (8) In the present embodiment, since the press-fitting
portions 43, which serve as the attaching portions that engage with
the inner wall of the circuit accommodating portion 21d, are formed
on the substrate support member 31, extra components for attaching
the control circuit member 25 on the motor 1 are unnecessary. This
prevents increase in the number of components.
[0068] The embodiments of the present invention may be modified as
follows.
[0069] In each of the above embodiments, only one securing
projection 45 is provided, but two or more securing projections 45
may be provided. Also, the securing portion 47 of the present
embodiment may have substantially the same structure as the
securing projection 45.
[0070] In each of the above embodiments, the Hall IC 33 is used as
the rotation detecting element, but for example, a magnetic
resistance element may be used.
[0071] In each of the above embodiments, the present invention is
embodied in the control circuit member 25 provided in the motor 1
for power window apparatus, but may be applied to motors other than
the motor 1 for power window apparatus. Also, the present invention
may be applied to a circuit component provided in apparatuses other
than motors. For example, the present invention may be applied to a
motor for other apparatuses such as a sunroof apparatus, a slide
door apparatus, and a back door apparatus.
[0072] In the second embodiment, the first bent portions 57 of the
control terminals 51, 52 are configured to be located in the
through holes 49a, but may also be located, for example, outside
the through holes 49a and on the end of the through holes 49a
closer to the circuit substrate 32. The through holes 49a are
formed at positions corresponding to the first bent portions 57 of
the control terminals 51, 52 (at positions where the first bent
portions 57 and the base portion 41 overlap in the front and rear
direction).
[0073] In the second embodiment, the control terminals 51, 52 are
formed into the crank shape by the first bent portions 57 and the
second bent portions 55, but the control terminals 51, 52 may be
formed into, for example, an L-shape by omitting the second bent
portions 55.
[0074] In the second embodiment, several (nine in total) control
terminals 51, 52 are provided. However, one to eight, or ten or
more control terminals 51, 52 may be provided.
[0075] In each of the above embodiments, the press-fitting portions
43, which serve as the attaching portions to the motor 1, are
provided on the substrate support member 31. However, the
press-fitting portions 43 may be omitted and a member for attaching
the control circuit member 25 to the motor 1 may be separately
provided.
[0076] In each of the above embodiments, the circuit substrate 32
is inclined with respect to the axial direction of the rotary shaft
10. However, the circuit substrate 32 may be parallel to the rotary
shaft 10.
* * * * *